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. f L METALWORKING PRocEs Filed May 16, 1952 16 Sheets-Sheet 16 chau@ w; Hqmltb ATTO qu 355 Patented oct. 421', 193s UNITED STATES PATENT `ori-ICE MErALwonKrNG PROCESS ClarenceW. Hazelett, Rocky River, Ohio Application May 16, 1932, serial No. 611,603

` tessuto Thls invention relates to metal products,andv to y methods of and apparatus for producing the same,

and more particularly, to the forming of metal `from a molten state, and to metal 'shapes and articles so formed, and has for an object the provision of new andl improved methods, new and improved apparatus, and new and improved metal products, thereunto appertaining.

In the drawings accompanying this specication and forming a part of this application, I have shown, for purposes of illustration, several embodiments which my invention may assume, and in these drawings:

Figures 1 and 2 are together a diagrammatic side elevation of an embodiment of my .invention Figure 3 is a vertical longitudinal sectional view of a mechanism for feeding molten metal,

Figure 4 is a plan view of the feeding mechanism;l

illustrated in Figure 3,

Figure 5 is a side elevation of another embodiment of metal feeding mechanism,

, Figure 6 is a plan view of the feeding mechanism illustrated in Figure 5,

Figure 7 is a vertical sectional view of still another embodiment of metal feeding mechanism, Figure 8 is a fragmentary plan of a rolling mechanism,

` Figure 9 is a vertical sectional View taken on the line --Sl of Figure 8,

Figure 10 is a vertical sectional view of another in longitudinal section of a further embodiment of Y rolling mechanism,

Figure 14 is a transverse sectional view taken on the line iii-,ld of Figure 13,

Figure 15 is a transverse sectional view taken on the line lS-l5 of Figure i3,

Figure 16 is a transverse sectional view taken on vthe line lt-IG of Figure 13,

ment of vroll andend dam mechanism,

Figure 22 is a plan view of another embodiment of roll and end dam mechanism, y

Figure 23 is a vertical sectional view taken on the line 23--23 of Figure 22, Figure 24 is a fragmentary plan view of.another embodimentof roll and end dam mechanism,

Figure 25 is a vertical sectional view taken on the line 25--25 of Figure 24, I

y Figure 26 is a fragmentary plan view of another embodiment of roll and end dam mechanism.

Figure 27 is a vertical sectional view taken onv Figure 29 is a vertical sectional view taken 'on the line 29-29 of Figure 28,

Figure 30 is a view, partlyin side elevation and vpartly in vertical longitudinalsectiompf another embodiment of roll and end dam mechanism,

Figure 31 is an end elevation of the means illustrated. in Figure 30,

Figure 32 is a perspective view of parts of the end dam mechanism illustrated in Figures 30 and 31,

Figure 33 is a fragmentary vertical section of a rolling and cooling means,

Figure 34 is a side elevation of another embodiment of rolling and4 cooling mechanism,

Figure 35 is a plan view of rollingmechanism particularly adapted for forming bars of angular cross-section,

Figure 36 is a plan View of rolling mechanism particularly adaptedfor forming bars ci channel cross-section,

Figure 37 is a plan view o rolling mechanism particularly adapted for forming bars oi I cross section, t

Figure 38 rolling mechanism having corrugated surfaces,

Figure 39 is a fragmentary vertical sectional view oi rolling mechanism, illlustrating several stages of solidication of metal with respect thereto,

Figure 40 is a iront elevation of an embodiment wherein'the metal is supplied by a gate,

AFigure 41 is a section parallel to the plane of Figure 40, on the line 4i-4l of Figure 42, l Figure 42 is a top plan view o f the embodiment of Figure 40,

Figure 43 is a horizontal section, on the line 43-'43 of Figure 41, v

Figure 44 is a side elevation of the embodiment or Figure 40,

Figure 46 1s a detail viewshowing means :er heating the rolls,

5' Figure '47 is a detail view showing means for cooling the rolls selectively,

Figure 48 is a view showing one form of suitable torque indicator,

Figure 49 is a diagrammatic representation of l a driving motor for automatic control,

lFigure 50 is a diagrammatic representation of alternative automatic control means.

' Figure 5l is a reproduction of a micro-photograph of a strip of steel rolled according to my l process. while Figure 52 is a reproduction ,of a micro-photograph of the strip, after rerolling.

. In Figures 1 and 2 I have shown a horizontal mill 50 comprising a pair of horizontal rolls 5I 20 and 52 mounted in juxtaposed parallel relation and backed by a pair of backing `rolls 5 3. The rolls 5l and 52 vare cooled, as by water delivered to the spaces between the rolls 5I and 52 and the respective backing rolls 59, as by ducts 54 25 controlled by valves 55, and are shown as driven l by a motor 56 connected -to the rolls 5I and 52 by a connection indicated diagrammatically at l1. Variable speed of rotation of the rolls 5l and 52, if desired. may be secured in any suitable 30 manner, as by using for the motor 58 a variable speed motor, or by inserting in the drive 51 a,

variable speed device V of any suitable construction. v

Mounted on the roll 5| area pair of end dams '35 n cooperating with the reus sl and s2 to denne between the rolls 5l and 52, above the points of tangency thereof a space 59 for the reception of molten metal. y

Mounted above the'mill 50 is a reservoir 69 40 adapted to receive molten metal from any suitable source (not shown), andto deliver'this molten metal to the space 59 between the rolls 5l and l2.. The rolls 5| and 52 being below the temperature of fusion ofthe metal, the metal -45 solidiiies contiguous the rolls 5l and 52, and the metal so solidified contiguous the rolls 5I and 52 is carried down to the bight. of the rolls, and issues as the continuous strip S.

With apparatus of this type the characteristics 5 0 of `the strip S depend at least in large part on the relation between the extent of the solidification contiguous the rolls 5i and 52 and the spacing between the rolls 5I and 52. With the solidification entirely insuillcienttlieY molten coreA will 5 fuse through the solidified faces, and the metal will pour through as a molten stream. With somewhat greater solidification the relatively thicker solidified surfaces will be suiliciently thick to prevent fusion through by the relatively thino0 ner molten core, and the molten core will solidify between the solidified surfaces, uniting the solidilied surfaces to itself, and the strip S will be distinctly a cast strip. This characteristic seems to continue up to the point where the extent of V6:5` solidification is substantially equal to the spacing -between the rolls, but beyond that point there.

occurs this marked difference, that thereafter, by reason of the fact that the solidified metal delivered at the bight of the rolls is of greater thick- 7o ness than the 'spacing ofthe rolls, lthe strip is definitely a rolled strip.

I find, however, that the extent of solidification, and therefore, for any given spacing of the rolls ll and 52. the extent of solidication rela- 7s tive to the spacing of the rolls, is a result of vari- 2,058,447 Figure 451s e detail or the gate biesing'and,

ous factors, including the nature of the metal itself, the temperature of the metal as deliveredl to the rolls, the length of the arc of contact of the metal withthe rolls, the temperature of the rolls, and the speed of rotation of the rolls, and

concurrently, that for any given metal, I can maintain any desired extent of solidification, and therefore, with any given spacing of the rolls,

any desired extent of solidification relative to the spacing of the rolls, by maintaining constant the relation VVbetween;tliegvarious factors. And that I can maintain Ythis relation constant by controlling any one or more of the factors, to compensate for variation in one or more other factors.

For example, with any given metal, I may maintain constant extent of solidification, and with a given spacing of the rolls, constant extent'of solidification relative to the spacing of the rolls, despite variation in other factors, by coordinate variation in the speed of rotation of the rolls, as by variation in the speed of the motor '56 itself, or by means of the variable speed device V. Or I may accomplish the result by coordinately varying the arc of contact of the metal with the rolls, as by varying the flow of metal to the space 59 between the rolls, or by varying the effective height of the end dams, to vary the vertical extent of the space 59. Or I may accomplish theresult by coordinatelyvarying the temperature of the metal, as by actual variation of the temperature of the metal as supplied, or by heating the metal in the space 59 in any suitable manner, such as by the passage of electric current therethrough, or, in the case of magnetic metal, by inducing -currents therein. Or I may the temperature of the rolls, as by coordlnately varying the cooling thereof, as, for example. by varying the valves 55 to varythe amount of cooling fluid supplied by the ducts 54, or by varying the temperature of the cooling fluid itself, as by intermixing steam and water in varyingproportion. Or if the temperature of the cooling fluid is itself variable, I may maintain constant cooling of the rolls by coordinately varying the quantity of cooling fluid supplied to the rolls. And of course I may accomplishthe maintenanceof constant extent of solidification, and of constant extent of solidiiicationrelative to the spacing of the rolls, by any combination of coordinate variations of the factors.

. Considering the factors mentioned, the extent of solidification is increased byV decrease in the speed of rotation of the rolls, by decrease in, the temperature ofthe metal, by decrease in the roll temperature, and so far as I am now aware, by increase in the arc of contact of the metal with the rolls.

But however the control may be accomplished, coordination of the factors governing the extent of solidification is of extreme importance,.since variation, even if small, will materially affect the quality and characteristics .of the product, and of course, if larger.' may result in' appreciable damage and destruction, either by thepassage of metal through the rolls without solidification, or,

in the other direction, by over-solidification to an extent' sufficient to wreck the Whereas by suitable coordination it ispossible to obtain and l accomplish the result by coordinately varying continuously to maintain any desired condition, e

thickness somewhat greater than the spacing of the rolls, whereby the metal is rolled bythe rolls, and the strip S is a rolled strip.

' as, for example, solidication of the metal in a In' Figures 1 and 2 I have shown subsequent processing which may be in part or in whole applicable to a strip S of any characteristics, but

which is presented as particularly applicable to a rolled strip.

mounted-adjacent the mill 58 for the passage of the strip S therethrough, and containingreducing gases operative both to reduce any oxide existent on the surface of the strip and also, to prevent or diminish such formation of oxide subsequently. i

Adjacent the chamber 6i is mounted a re-rolling mill 62, for re-rolling the strip, either to vary its characteristics or to vary its size, or both, as may be desired.

Beyond the re-rolling mill 62 the strip S passes successively: through a normalizin furnace 63, for heat treating the strip; throug a pickling tank 164, containing acid or other suitable solution for removing any oxide present on the surface of the strip; through a washing tank 65, for washing the strip S after the emergence thereof from the pickling tank 64; .and through a leveler` 66, for leveling out any irregularities in the strip. The strip S is shownas then passing to a shear 61, to be cut into lengths, and then as passing in this form to a forming press 68, to be formed and shaped as desired.4 It will be understood, however, that these operations to some extent may be performed in an order other than that illustrated, and also, that any or all of these operations may be omitted, all as may be desired. It is to be noted, however, that such of these operations as are included may operate on the stripwhile the strip retains its original heat, and without any reheating.

In this connectionA it mayl be added, that the passage of the strip immediately through the reducing chamber 6I and the re-rolling mill 62, so thatthe strip reaches the re-rolling mill 62 before any oxide hasformed in any surface cracks presentv in the strip S, is most effective to completely obliterate any trace of any such cracks, as though such cracks had never existed.

From the' foregoing, it will be apparent that by use of the apparatus described, metal from a molten state may be formed into a solid continuous strip, and treated and fabricated into a` finished article, by a succession of instrumentalities operating continuously, while the metal still is hot and connected Withthe parent body of molten metal in the space 59 between the rolls 5i and 52.

In Figures 3 and 4 I have shown a detailed embodiment of means for supplying the molten metal to the rolls, corresponding to the reservoir 68 heretofore referred to, and comprising a reservoir 69, lined with fire brick to resistvthe actionv of the molten metal, and mounted between the forward ends of a pair of arms 18, the rear ends of which are xed to a shaft'll journaled in a support 12. A rearwardly extending arm 13 is also fixed to the shaft 1l at one end thereof; and is provided with an adjustable counterweight 14 for counterbalancing the weight of the reservoir 69 and of the metal contained therein. Molten metal is supplied to the reservoir 69 through a submerged outlet 15 provided in the bottom of a ladle 16, and the flow of metal through this opening may be controlled by means of a vertically reciprocable valve member 11 carried at the lower end of a rod 526 operated in any suitable manner. The rear wall of the reservoir 69 may be inclined, as indicated at 18, to prevent 'Succession O'f Waves 01' surges.

the metal delivered to the reservoir 69 from contacting too forcibly therewith, and for distributing the metal transversely of the reservoir 69 and deilecting it in a forward direction. The forward end of the reservoir 69 is provided with a dam 19 having a serrated upper edge forming a series of notches through which the metal overflows to the space 59 between the rolls 8| and 82. By means of this particular construction, the metal supplied to the reservoir 69 from the ladle 16 is allowed to form a pool 9| at the rear of the dam 19, whereit may become quiescent if in an effervescent state, and where it becomes distributed in a lateral direction.l

This dam 19may, however, be formed with a straight: overiiow edge if desired, and the molten metal may be caused to flow over'the dam in a Tothis end the reservoir 69 is constructed to be periodically tilted by means of a link 83 pivotally connected at its upper end to the end of the arm 13 and provided at its lower end with an eccentric strap 84 engaging a. constantly rotating eccentric 85. The successive tilting ofthe reservoir 69 by the eccentric 85 causes the molten metalto flow over the 'dam 19 in a relatively broadv stream of substantially uniform depth.

centrally between the rolls 8l and 82. The baiiie 86 is carried by a bracket 81 which is pivotally mounted at its upper end, as indicated at 88, and which may be adjusted toward and away7 from the reservoir 69 by means of an adjusting screw 89. The baiiie 86 may be heated by a flame issu- A its velocity, and further, tends tofspread the metal, so that it' surely will be distributed uniformly throughout the length of the rolls 8| andv 'I'he vbaille 86 also functions to deect the metal downwardly into the pool at a point of greatest depth, so that it Will not have a tendency to melt the metal which ha's become solidified along the surface of these rolls,'an action which would tend to cause the metal to pass through the rolls before itA has become solidified .to the desired extent.

In Figures` 5 and 6 I have shown molten metal being supplied to a reservoir 92 from a. pair of Bessemer converters, indicated diagrammatically at 93 and 94. These converters may be operated alternately, to obtain a substantially continuous supply of metal to the rolls. The molten metal from the converters 93 and 94 1s delivered toa chute 95 having converging side walls, which in turn supplies the metal to the reservoir 92. If the lmetal delivered from the converters be in an effervescent state, it will give 'up at least a considerable part of its gases while traversing the chute 95 and the reservoir 92.

In Figure 7 there is shown an arrangement in which molten metal is delivered to a reservoir 96 directly from a top-pour ladle 91, having a pouring spout 98 and a removable cover 99. `This ladle is pivotally mounted adjacent its forward end, as indicated at |88, and may .be tilted by means of a chain |8I secured to the rear end` thereof. A bane' luz is disposed within the ladle 91 in spaced relation with the bottom thereof, so that the molten metal passing to the spout 98 will flow downwardly beneath the baille, thus excluding any dross from the metal delivered to the reservoir 96. cover 99, to project a flame in the vicinity of the metal flowing through the spout 98, in order to minimize oxidation and reduce effervescence. In this particular embodiment the reservoir is fixedly mounted upon a bracket |05, and is enclosed within a housing |06 supplied with reducing gas provided to prevent oxidation of the metal being delivered to the rolls. In Figures 8 and 9 I disclose rolling mechanism including rolls |01 and |08 corresponding to the rolls 5| and 52. When the apparatus is initially 5\set in operation, it is desirable that the forming roHFHind |08 occupy a position in which their surfaces anpengawent, so that the molten metal will not run downwardlgwbetween Aburner |04 is provided in the 'the rolls |01 and 08, and the thickness of the bar or strip of metal rolled thereby. This distance may be regulated, to roll metal of the thickness desired, by accurately adjusting'the position of the stop |22, by means of the operating handle 5 334 connected to the pinion |30, and to the position indicated by the pointer |3I. o

The rolls |01 and |08 may be provided with scrapers |32, for preventing the metal from sticking thereto, and for removing scale therefrom, 10

and may be cooled by water sprayed thereon from pipes |33.

In Figure 10 vthere is shown another type of construction comprising forming rolls `v|34 each having an inner' core `|35 within an outer shell 15 |36 of an internal diameter considerably in excess of the outside diameter of the core |35. The core |35 and shell |36 engage at the bight of the before it has had time to become sucientry"\r0lls |34, and are provided with external and solidified to emerge as a strip. To this end means are provided for yieldably urging the forming roll |08 toward the roll |01. In this particular construction, the roll |01 is journaled in a xed bearing |09, but the roll |08, and its associated backup roll |0, are mounted in bearings and ||2 provided in a carriage ||3 mounted for horizontal adjustment in a slide ||4. The bearing v||| of the roll |01 may be a half-bearing, as shown, so as to permit the roll |08 to be quickly and easily removed or assembled in position.

The inner end of the carriage ||3 is provided with a recess ||5 formed with longitudinally extending slots ||6 and with a plate ||1 secured thereto by means of screws ||8 and provided with a centrally disposed opening Il!! surrounded by an annular flange or collar |2|` A spring |2| is interposed between the end of the slide ||4 and the plate ||1, and urges the carriage ||3, together with the forming roll |08 and the associated back-up roll ||0, toward the iixed roll .|01. Disposed within the recess i5 is an adjustable stop |22 provided with diametrically disposed key portions |23 for sliding engagement with the slots ||6 and also with an internally screw threaded tubular member |24 which extends rearwardly through the opening ||9 in the plate ||1 for engagement by a screw |25 rotatably mounted in a bearing |26 provided in the en d of the slide ||4 and maintained against displacement by means of a pair of arcuate collar members |21 secured to the inner face of the slide ||4 for engagement with an annular groove |28 provided in the screwT |25. The other end of the screw |25 is provided with a bevelled gear |29 which is adapted to be rotated by means of a bevelled pinion |30 fixed to one end of a shaft 333 provided with an operating handle 334 and journaled in a bearing 335 carried by abracket 336 fixed to the side of the slide I4. A pointer |3| is secured to the end of the slide 4 for cooperatipn with a series of calibrations provided on thef'periphery fthe bevelled gear |29.

When the apparatus is not in operation, and there is no metal between the rolls |01 and |08, the spring |2| urges the roll |08 into engagement with'the roll |01. As-soon, however, as metal is introduced'into the space between the converging-'upper portions of the rolls |01 and |08, and becomes solidified through contact therewith, the rotation of the rolls |01 and |08 carries the solidified metal downwardly between the rolls, thus causing the roll |08 to recede against the action of'the spring |2 luntil the carriage ||3 abuts the adjustable stop |22, which determines the amount of separation between interna intermesh at that po' The shells |36 are supported byorolls "ligand are cooled both externally and internally by a cooling medium such as water'or live steam, or a combination thereof, issuing from nozzles |40 and 25 |4| located respectively outside the shell |36 and between the core |35 and shell |36, at a point diametrically opposite the point of tangency between the core |35 and the shell |36. The now of cooling fluid to the nozzles |40 and |4| may be 30 controlled by valves |42 provided in supply pipes |43, -thus to vary the temperature of the rolls |34, to controllably affect solidification of the metal, as hereinbefore pointed out. By means of this construction the rolls |34 present substantially 35 solid and unyielding surfaces to the metal being rolled, yet at the same time permit the shell to be cooled both internally and externally. It will be noted also that the shell, the part in actual contact with the metal,` is relatively thin, as 40 compared to the remainder of the roll, and consequently dissipates heat very quicklyv when subjected to the action of the cooling medium issuing from the nozzles |40 and |4I, but presents what is in effect a continuous and solid roll at the point 45 of action, where it is subjected to strain. Also, in this construction the. outer shells are relatively inexpensive, and may be quickly and'easily removed for replacement or repairs, without disrupting the associated mechanism.

In Figures 11 and 12 there is shown a roll |52 `comprising a solid steel core |44 having an outer shell |45 of cast iron. This provides a'very inexpensive and ecient construction, in that the roll is provided with a rough relatively tractive 55 surface which may be chiseled on when worn and replaced by a new shell. In this construction the roll |46 is provided with a driving shaft |41 provided with a threaded portion |48, and an annular end dam |49 is secured to the end of 60 the roll |46 by means of screws |50, and is reinforced by means of a back-up nut |5| threaded onto the portion |48 of the shaft |41. The outer periphery of the end dam |49 overlaps the ends of the adjacent cooperating roll |52, to provide a 65 space between thev rolls |46 and |52 adapted to receive the molten metal, and is provided witha 'plurality of peripheral teeth |53 formed with rolls, and the interference; with operation of the 75 ^eth`|31 and |38, respectively, which 20 The teeth |53 cooperate with the 70 

